EP1634693B1 - Mixture of sinterable powders for rapid prototyping - Google Patents

Mixture of sinterable powders for rapid prototyping Download PDF

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Publication number
EP1634693B1
EP1634693B1 EP04030428A EP04030428A EP1634693B1 EP 1634693 B1 EP1634693 B1 EP 1634693B1 EP 04030428 A EP04030428 A EP 04030428A EP 04030428 A EP04030428 A EP 04030428A EP 1634693 B1 EP1634693 B1 EP 1634693B1
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Prior art keywords
mixture according
fibers
weight
mixture
present
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German (de)
French (fr)
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EP1634693A1 (en
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Franco Cevolini
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CRP Technology Srl
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CRP Technology Srl
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C08L77/06—Polyamides derived from polyamines and polycarboxylic acids
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B29C64/141—Processes of additive manufacturing using only solid materials
    • B29C64/153—Processes of additive manufacturing using only solid materials using layers of powder being selectively joined, e.g. by selective laser sintering or melting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y70/00—Materials specially adapted for additive manufacturing
    • B33Y70/10—Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/06—Elements
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/14—Glass
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C08L77/02—Polyamides derived from omega-amino carboxylic acids or from lactams thereof
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L77/00—Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Compositions of derivatives of such polymers
    • C08L77/10—Polyamides derived from aromatically bound amino and carboxyl groups of amino-carboxylic acids or of polyamines and polycarboxylic acids

Definitions

  • the present invention relates to a mixture of sinterable powders for rapid prototyping, particularly for SLS (Selective Laser Sintering) processes.
  • the resulting prototype can be used as a replacement of the actual component during tests for example of the photoelastic type in order to determine the mechanical characteristics of said component.
  • the rapid prototyping process is organized into several steps: initially, the component being studied must be designed with the aid of a three-dimensional solid- or surface-modeling system, so as to obtain a three-dimensional CAD model, which is then converted into a format that can be read by the prototyping machine generally an STL (stereolithography) format.
  • STL stereolithography
  • This conversion consists in approximating the surface of the model by means of a plurality of juxtaposed triangles, which are arranged adjacent to each other so as to cover all of said surface.
  • the model in the STL format is sectioned by the software that manages the rapid prototyping machine with a plurality of parallel planes that are spaced with an appropriate thickness.
  • Each plane is one of the layers of material that the machine subsequently superimposes; the contiguous layers are bonded to each other already during the construction of the prototype.
  • One of the known rapid prototyping technologies is constituted for example by the so-called SLS (Selective Laser Sintering) method, which is based on the consolidation of the powders by means of a sintering process obtained by using a laser.
  • SLS Selective Laser Sintering
  • the machine used to perform this method is substantially constituted by a vertically-movable platform on which the powder is deposited, said powder being retained inside the machine at a temperature that is just below its melting point, so as to constitute a layer of uniform thickness, which is struck by the laser only at the region that matches the corresponding cross-section of the model to be provided, causing it to sinter.
  • the platform then moves downward by an extent that corresponds to the thickness of material that has been deposited, and a new layer of powder is superimposed on the preceding one and sintered as described above, so as to solidify and grip the underlying layer.
  • the material currently used in rapid prototyping processes and particularly in the SLS method is generally constituted by a mixture of powders of the polyamide type, optionally with the addition of powders of various kinds having a reinforcing effect.
  • the reinforcement fibers can be mixed to a matrix formed by powder particles of a metallic or thermoplastic material, or they can be originally embedded into grains or particles of the material.
  • the aim of the present invention is to provide a mixture of sinterable powders for rapid prototyping that allows to optimize the characteristics of mechanical strength of the models obtained with it.
  • a mixture of sinterable powders for rapid prototyping which comprises a polymeric powder matrix, a reinforcement material in the form of fibers and all the other features defined by the main independent claim.
  • the polymeric matrix is preferably of the polyamide type and may comprise for example nylon.
  • Such reinforcement material may be of the polymeric type, preferably constituted by aramid-type fibers, of the inorganic type, preferably constituted by glass and/or carbon fibers, or of a polymeric and inorganic type.
  • aramid fibers is used to designate fibers made of aromatic polyamides with an aromatic group content of more than 85%.
  • the aramid-type fibers can be constituted for example by fibers of poly-paraphenyleneterephthalamide known under the brand name Kevlar, and provided by the DuPont Company.
  • the fibers that constitute the reinforcement material may be of a chopped or milled type.
  • chopped fibers are fibers with a length between 3 and 6 mm and milled fibers are fibers with a length between 150 and 450 ⁇ m.
  • the mixture may further comprise material of a substantially glassy type in the form of microspheres, powdered aluminium and powdered graphite.
  • polymeric matrix between 20% and 99%
  • reinforcement material in the form of fibers between 1% and 80%
  • glassy material in the form of microspheres between 0% and 70%
  • powdered aluminum between 0% and 70%
  • powdered graphite between 0% and 40%.
  • polymeric matrix, the reinforcement material in the form of fibers, the glassy material in the form of microspheres, the powdered aluminum and powdered graphite are preferably present in the following quantities, which are mutually independent of each other and are expressed as percentages of the total weight of the mixture: polymeric matrix, between 50% and 90%; reinforcement material in the form of fibers, between 10% and 50%; glassy material in the form of microspheres, between 15% and 25%; powdered aluminum, between 10% and 25%; powdered graphite, between 0% and 10%.
  • the mixture according to the invention can be prepared by mechanical mixing (for example, inside mixers in which the appropriate quantities of the various components are introduced) or by pneumatic mixing (for example, by blowing air into silos that contain the various components); alternative embodiments are of course not excluded.
  • the resulting mixture is ready for use and can therefore feed conventional rapid prototyping machines, particularly machines for performing the SLS method.
  • said mixture can be applied in all conventional fields of use of rapid prototyping, such as for example the manufacture of parts of vehicles, electrical household appliances, design items or others.
  • the ultimate tensile strength of the material obtained by sintering the mixture according to the present invention is in fact on the order of magnitude of 55-60 MPa, whereas the ultimate tensile strength of the materials conventionally used in rapid prototyping is on the order of magnitude of 40-48 MPa.
  • a first mixture of sinterable powders for rapid prototyping that can be obtained from the following components: polymeric matrix 60% reinforcement material in the form of fibers 30% glassy material in the form of microspheres 10% powdered aluminum 0% powdered graphite 0%
  • a second mixture of sinterable powders for rapid prototyping that can be obtained from the following components: polymeric matrix 50% reinforcement material in the form of fibers 20% glassy material in the form of microspheres 15% powdered aluminum 10% powdered graphite 5%

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  • Chemical & Material Sciences (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Optics & Photonics (AREA)
  • Manufacturing & Machinery (AREA)
  • Physics & Mathematics (AREA)
  • Civil Engineering (AREA)
  • Composite Materials (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Powder Metallurgy (AREA)
  • Dental Preparations (AREA)

Abstract

A mixture of sinterable powders for rapid prototyping, comprising a polymeric matrix in powder form and a reinforcement material in the form of fibers, optionally with the addition of material of a substantially glassy type in the form of microspheres, powdered aluminum and/or powdered graphite.

Description

  • The present invention relates to a mixture of sinterable powders for rapid prototyping, particularly for SLS (Selective Laser Sintering) processes.
  • As it is known, rapid prototyping is a technique that has been developed rather recently and allows to obtain automatically the prototype of a mechanical component starting from its corresponding CAD drawing, regardless of its geometry, in a short time and at a relatively low cost.
  • The resulting prototype can be used as a replacement of the actual component during tests for example of the photoelastic type in order to determine the mechanical characteristics of said component.
  • It is also known that there are various rapid prototyping technologies, which in any case entail superimposing a plurality of layers of material, which are mutually coupled so as to obtain a model, possibly a scale model, of the actual component.
  • These technologies differ in the manner in which the layers of material are applied during the construction of the prototype; in particular, each technology is based on a different physical principle, which determines the nature and state of final aggregation of the materials used.
  • The rapid prototyping process is organized into several steps: initially, the component being studied must be designed with the aid of a three-dimensional solid- or surface-modeling system, so as to obtain a three-dimensional CAD model, which is then converted into a format that can be read by the prototyping machine generally an STL (stereolithography) format.
  • This conversion consists in approximating the surface of the model by means of a plurality of juxtaposed triangles, which are arranged adjacent to each other so as to cover all of said surface.
  • The model in the STL format is sectioned by the software that manages the rapid prototyping machine with a plurality of parallel planes that are spaced with an appropriate thickness.
  • Each plane is one of the layers of material that the machine subsequently superimposes; the contiguous layers are bonded to each other already during the construction of the prototype.
  • Finally, it is possible to subject the resulting prototype to cleaning and finishing operations or to other kinds of treatment.
  • One of the known rapid prototyping technologies is constituted for example by the so-called SLS (Selective Laser Sintering) method, which is based on the consolidation of the powders by means of a sintering process obtained by using a laser.
  • The machine used to perform this method is substantially constituted by a vertically-movable platform on which the powder is deposited, said powder being retained inside the machine at a temperature that is just below its melting point, so as to constitute a layer of uniform thickness, which is struck by the laser only at the region that matches the corresponding cross-section of the model to be provided, causing it to sinter.
  • The platform then moves downward by an extent that corresponds to the thickness of material that has been deposited, and a new layer of powder is superimposed on the preceding one and sintered as described above, so as to solidify and grip the underlying layer.
  • The process is repeated until the complete model is obtained.
  • The material currently used in rapid prototyping processes and particularly in the SLS method is generally constituted by a mixture of powders of the polyamide type, optionally with the addition of powders of various kinds having a reinforcing effect.
  • Although these mixtures of sinterable powders allow to obtain models of more than satisfactory quality, they are not free from drawbacks, including the fact that the resulting models have limited moduli of elasticity and low ultimate tensile strengths.
  • It is known from documents WO 2005/090448 A1 and WO2005/090449 A1 , that were published after the priority of the present application, a process for producing a material, in powder or granular form to be used for rapid prototyping based on the SLS technique, in which the composition of this material includes reinforcement fibers that are provided in order to reinforce the structure of the prototypal parts obtained by this technique.
  • The reinforcement fibers can be mixed to a matrix formed by powder particles of a metallic or thermoplastic material, or they can be originally embedded into grains or particles of the material.
  • Further information on solutions and materials, in particular including reinforcement fibers, for use in the field of rapid prototyping based on the SLS technique can be found in document DE 19942071 A1 .
  • It is even mentioned document WO 96/30195 A which refers to a composition for a mixture intended for use in rapid prototyping, even if not including in its composition reinforcement fibers.
  • The aim of the present invention is to provide a mixture of sinterable powders for rapid prototyping that allows to optimize the characteristics of mechanical strength of the models obtained with it.
  • In view of this aim and of other objects that will become better apparent hereinafter, according to the present invention a mixture of sinterable powders for rapid prototyping is provided which comprises a polymeric powder matrix, a reinforcement material in the form of fibers and all the other features defined by the main independent claim.
  • The polymeric matrix is preferably of the polyamide type and may comprise for example nylon.
  • Such reinforcement material may be of the polymeric type, preferably constituted by aramid-type fibers, of the inorganic type, preferably constituted by glass and/or carbon fibers, or of a polymeric and inorganic type.
  • The expression "aramid fibers" is used to designate fibers made of aromatic polyamides with an aromatic group content of more than 85%.
  • The aramid-type fibers can be constituted for example by fibers of poly-paraphenyleneterephthalamide known under the brand name Kevlar, and provided by the DuPont Company.
  • The fibers that constitute the reinforcement material may be of a chopped or milled type.
  • Conventionally, chopped fibers are fibers with a length between 3 and 6 mm and milled fibers are fibers with a length between 150 and 450 µm.
  • The mixture may further comprise material of a substantially glassy type in the form of microspheres, powdered aluminium and powdered graphite.
  • The polymeric matrix, the reinforcement material in the form of fibers, the glassy material in the form of microspheres, the powdered aluminium and the powdered graphite are present in the following quantities, which are mutually independent and are expressed as percentages of the total weight of the mixture:
    polymeric matrix, between 20% and 99%; reinforcement material in the form of fibers, between 1% and 80%; glassy material in the form of microspheres, between 0% and 70%; powdered aluminum, between 0% and 70%; powdered graphite, between 0% and 40%.
  • The polymeric matrix, the reinforcement material in the form of fibers, the glassy material in the form of microspheres, the powdered aluminum and powdered graphite are preferably present in the following quantities, which are mutually independent of each other and are expressed as percentages of the total weight of the mixture:
    polymeric matrix, between 50% and 90%; reinforcement material in the form of fibers, between 10% and 50%; glassy material in the form of microspheres, between 15% and 25%; powdered aluminum, between 10% and 25%; powdered graphite, between 0% and 10%.
  • According to conventional operating methods and depending on the quantities to be produced, the mixture according to the invention can be prepared by mechanical mixing (for example, inside mixers in which the appropriate quantities of the various components are introduced) or by pneumatic mixing (for example, by blowing air into silos that contain the various components); alternative embodiments are of course not excluded.
  • The resulting mixture is ready for use and can therefore feed conventional rapid prototyping machines, particularly machines for performing the SLS method.
  • Conveniently, said mixture can be applied in all conventional fields of use of rapid prototyping, such as for example the manufacture of parts of vehicles, electrical household appliances, design items or others.
  • Advantageously, it has been found by means of laboratory tests that the models provided with the mixture according to the invention have a greater mechanical strength than prototypes obtained with conventional materials, both at ambient temperature and at high temperatures.
  • Moreover, significant increases in elastic modulus and in the ultimate tensile strength of the material have been observed.
  • The ultimate tensile strength of the material obtained by sintering the mixture according to the present invention is in fact on the order of magnitude of 55-60 MPa, whereas the ultimate tensile strength of the materials conventionally used in rapid prototyping is on the order of magnitude of 40-48 MPa.
  • The following examples are given only as an illustration of the present invention and must not be understood as limiting its scope as defined by the accompanying claims.
    • EXAMPLE 1
  • A first mixture of sinterable powders for rapid prototyping that can be obtained from the following components:
    polymeric matrix 60%
    reinforcement material in the form of fibers 30%
    glassy material in the form of microspheres 10%
    powdered aluminum 0%
    powdered graphite 0%
    • EXAMPLE 2
  • A second mixture of sinterable powders for rapid prototyping that can be obtained from the following components:
    polymeric matrix 50%
    reinforcement material in the form of fibers 20%
    glassy material in the form of microspheres 15%
    powdered aluminum 10%
    powdered graphite 5%
  • The persons skilled in the art would readily understand that other mixtures of sinterable powders may be prepared, based on the disclosure of the invention set forth above, all of which however would be considered as comprised within the scope of the claims.
  • The disclosures in Italian Patent Application No. MO2004A000227 from which this application claims priority are incorporated herein by reference.

Claims (23)

  1. A mixture of sinterable powders for rapid prototyping, comprising a polymeric matrix in powder form,
    wherein said mixture comprises a reinforcement material in the form of fibers, and
    wherein said fibers are of the chopped and/or milled type, with said chopped fibers having a length between 3 and 6 mm and with said milled fibers having a length between 150 and 450 µm.
  2. The mixture according to claim 1, characterized in that said reinforcement material is of a substantially polymeric and/or inorganic type.
  3. The mixture according to claim 2, characterized in that said polymeric reinforcement material is of the aramid type.
  4. The mixture according to claim 2, characterized in that said inorganic reinforcement material comprises at least glass or carbon or both.
  5. The mixture according to claim 3, characterized in that said aramid polymeric reinforcement material comprises at least Kevlar.
  6. The mixture according to one or more of the preceding claims, characterized in that said polymeric matrix is of a substantially polyamide type.
  7. The mixture according to claim 6, characterized in that said polyamide polymeric matrix comprises nylon.
  8. The mixture according to one or more of the preceding claims, characterized in that it comprises material of a substantially glassy type in the form of microspheres.
  9. The mixture according to one or more of the preceding claims, characterized in that it comprises powdered aluminium.
  10. The mixture according to one or more of the preceding claims, characterized in that it comprises powdered graphite.
  11. The mixture according to one or more of the preceding claims, characterized in that said polymeric matrix is present in quantities comprised between 20% and 99% by weight.
  12. The mixture according to claim 11, characterized in that said polymeric matrix is present in quantities comprised between 50% and 90% by weight.
  13. The mixture according to one or more of the preceding claims, characterized in that said reinforcement material is present in quantities comprised between 1% and 80% by weight.
  14. The mixture according to claim 13, characterized in that said reinforcement material is present in quantities comprised between 10% and 50% by weight.
  15. The mixture according to claim 8, characterized in that said glassy material in the form of microspheres is present in quantities comprised between 0% and 70% by weight.
  16. The mixture according to claim 15, characterized in that said glassy material in the form of microspheres is present in quantities comprised between 15% and 25% by weight.
  17. The mixture according to claim 9, characterized in that said powdered aluminium is present in quantities comprised between 0% and 70% by weight.
  18. The mixture according to claim 17, characterized in that said powdered aluminium is present in quantities comprised between 10% and 25% by weight.
  19. The mixture according to claim 10, characterized in that said powdered graphite is present in quantities comprised between 0% and 40% by weight.
  20. The mixture according to claim 19, characterized in that said powdered graphite is present in quantities comprised between 0% and 10% by weight.
  21. The mixture according to claim 1, further including glassy material in the form of microspheres, characterized in that said polymeric matrix, said reinforcement material in the form of fibers and said glassy material in the form of microspheres are present in the following quantities, by weight: polymeric matrix 60% reinforcement maternal in the form of fibers 30% glassy material in the form of microspheres 10%
  22. The mixture according to claim 1, further including glassy material in the form of microspheres, powdered aluminium and powdered graphite, characterized in that said polymeric matrix, said reinforcement material in the form of fibers, said glassy material in the form of microspheres, said powdered aluminium and said powdered graphite are present in the following quantities, by weight: polymeric matrix 50% reinforcement material in the form of fibers 20% glassy material in the form of microspheres 15% powdered aluminium 10% powdered graphite 5%
  23. A process for the preparation of a mixture of sinterable powders for rapid prototyping,
    wherein said mixture is prepared by mixing together a polymeric matrix in powder form and a reinforcement material in the form of fibers, and
    wherein said fibers are of the chopped and/or milled type, with said chopped fibers having a length between 3 and 6 mm and with said milled fibers having a length between 150 and 450 µm.
EP04030428A 2004-09-09 2004-12-22 Mixture of sinterable powders for rapid prototyping Revoked EP1634693B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
DE202004020897U DE202004020897U1 (en) 2004-09-09 2004-12-22 Mixture of sinterable powders for rapid prototyping, contains polymeric matrix in powder form and reinforcement material in form of fibers

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT000227A IT1337831B1 (en) 2004-09-09 2004-09-09 MIXTURE OF SINTERIZABLE POWDERS FOR QUICK PROTOTYPING.

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EP1634693A1 EP1634693A1 (en) 2006-03-15
EP1634693B1 true EP1634693B1 (en) 2009-04-01

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US (2) US20060052508A1 (en)
EP (1) EP1634693B1 (en)
AT (1) ATE427210T1 (en)
DE (1) DE602004020340D1 (en)
ES (1) ES2325323T3 (en)
IT (1) IT1337831B1 (en)

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ATE427210T1 (en) 2009-04-15
EP1634693A1 (en) 2006-03-15
IT1337831B1 (en) 2007-02-20
ITMO20040227A1 (en) 2006-03-10
US20060052508A1 (en) 2006-03-09
ES2325323T3 (en) 2009-09-01
DE602004020340D1 (en) 2009-05-14
US20100152356A1 (en) 2010-06-17

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